WO2022218872A1 - Module de pressage à bascule de produit cellulosique et son procédé d'utilisation - Google Patents

Module de pressage à bascule de produit cellulosique et son procédé d'utilisation Download PDF

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Publication number
WO2022218872A1
WO2022218872A1 PCT/EP2022/059510 EP2022059510W WO2022218872A1 WO 2022218872 A1 WO2022218872 A1 WO 2022218872A1 EP 2022059510 W EP2022059510 W EP 2022059510W WO 2022218872 A1 WO2022218872 A1 WO 2022218872A1
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WO
WIPO (PCT)
Prior art keywords
pressing
forming
toggle
cellulose
module
Prior art date
Application number
PCT/EP2022/059510
Other languages
English (en)
Inventor
Ove Larsson
Olle HÖGBLOM
Martin Ljungberg
Edward Guidotti
Björn ARLEROT
Patrik Larsson
Original Assignee
Pulpac AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/EP2021/059811 external-priority patent/WO2022218531A1/fr
Priority claimed from PCT/EP2021/059810 external-priority patent/WO2022218530A1/fr
Priority claimed from SE2151618A external-priority patent/SE2151618A1/en
Application filed by Pulpac AB filed Critical Pulpac AB
Priority to AU2022258535A priority Critical patent/AU2022258535A1/en
Priority to EP22720730.5A priority patent/EP4323182A1/fr
Priority to CA3215281A priority patent/CA3215281A1/fr
Priority to CN202280028110.1A priority patent/CN117203044A/zh
Priority to JP2023562983A priority patent/JP2024514892A/ja
Priority to US18/285,619 priority patent/US20240181739A1/en
Priority to TW111114474A priority patent/TW202302330A/zh
Publication of WO2022218872A1 publication Critical patent/WO2022218872A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/005—Control arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N5/00—Manufacture of non-flat articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B1/00—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen
    • B30B1/10—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/30—Feeding material to presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/30—Feeding material to presses
    • B30B15/302—Feeding material in particulate or plastic state to moulding presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B9/00—Presses specially adapted for particular purposes
    • B30B9/28—Presses specially adapted for particular purposes for forming shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/006—Controlling; Regulating; Measuring; Improving safety
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/02—Feeding or positioning sheets, blanks or webs
    • B31B50/10—Feeding or positioning webs
    • B31B50/102—Feeding or positioning webs using rolls, belts or chains
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/59—Shaping sheet material under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/0077—Shaping by methods analogous to moulding, e.g. deep drawing techniques
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B1/00—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen
    • B30B1/10—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism
    • B30B1/103—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by toggle mechanism operated by screw means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/74—Auxiliary operations
    • B31B50/742—Coating; Impregnating; Waterproofing; Decoating
    • B31B50/747—Coating or impregnating blanks or webs

Definitions

  • the present disclosure relates to a cellulose product toggle pressing module for forming non-flat cellulose products from an air-formed cellulose blank structure.
  • the disclosure further relates to a method for forming non-flat cellulose products from an air-formed cellulose blank structure using a cellulose product toggle pressing module.
  • cellulose product toggle pressing module according to the disclosure will be described primarily in relation to an example cellulose product forming unit having integrated fibre separating module, cellulose blank air-forming module, etc., but cellulose product toggle pressing module and associated method for using the same is not limited to this specific implementation and may alternatively be implemented and used in many other types of cellulose products manufacturing systems.
  • Cellulose fibres are often used as raw material for producing or manufacturing products. Products formed of cellulose fibres can be used in many different situations where there is a need for having sustainable products. A wide range of products can be produced from cellulose fibres and a few examples are disposable plates and cups, cutlery, lids, bottle caps, coffee pods, and packaging materials.
  • Forming moulds are commonly used when manufacturing cellulose products from cellulose fibre raw materials, and traditionally the cellulose products are wet-formed.
  • a material commonly used for wet-forming cellulose fibre products is wet moulded pulp.
  • Wet moulded pulp has the advantage of being considered as a sustainable packaging material, since it is produced from biomaterials and can be recycled after use. Consequently, wet moulded pulp has been quickly increasing in popularity for different applications.
  • Wet moulded pulp articles are generally formed by immersing a suction forming mould into a liquid or semi liquid pulp suspension or slurry comprising cellulose fibres, and when suction is applied, a body of pulp is formed with the shape of the desired product by fibre deposition onto the forming mould.
  • One development in the field of producing cellulose products is the forming of cellulose fibres in a dry-forming process, without using wet-forming. Instead of forming the cellulose products from a liquid or semi liquid pulp suspension or slurry, an air-formed cellulose blank structure is used. The air-formed cellulose blank structure is inserted into forming moulds and during the forming of the cellulose products the cellulose blank structure is subjected to a high forming pressure and a high forming temperature in the forming moulds.
  • Manufacturing of cellulose products by compression moulding of an air-formed cellulose blank structure may be performed in production lines or product forming units.
  • the manufacturing equipment commonly includes a pressing module comprising the forming moulds.
  • Other modules and components are arranged in connection to the pressing module, such as for example feeding modules, and blank dry forming modules.
  • the pressing module is normally a high capacity pressing module, such as large hydraulic or servo powered pressing machines, which may be used for forming other materials such as steel plates, since these modules are available as stand-alone off-the shelf machinery.
  • converter the customer normally investing in cellulose product forming units is called converter and has typically no or little skill in the engineering required to develop and integrate the necessary modules for a complete cellulose product forming unit, and there is thus a desire among converters to be able to purchase complete, fully integrated, standardized production forming units, that may be easily shipped, installed and made to run.
  • An object of the present disclosure is to provide a cellulose product pressing module for forming non-flat cellulose products from an air-formed cellulose blank structure, as well as an associated method for forming non-flat cellulose products from an air- formed cellulose using such a pressing module, where the previously mentioned problems are avoided. This object is at least partly achieved by the features of the independent claims.
  • a product forming unit for manufacturing non-flat cellulose products from an air-formed cellulose blank structure.
  • the product forming unit comprises a blank dry-forming module with a moveable forming wire, a toggle pressing module with a toggle press and a forming mould, and an electronic control system operatively connected to the forming wire and the toggle press; wherein the blank dry-forming module is configured for air forming the cellulose blank structure onto the forming wire; wherein the toggle press includes a pressing member movably arranged in a pressing direction, a toggle- mechanism drivingly connected to the pressing member, a pressing actuator arrangement drivingly connected to the toggle-mechanism; wherein the forming mould includes a moveable first mould part attached to the pressing member and a second mould part; wherein the electronic control system is configured for controlling operation of the pressing actuator arrangement for performing pressing operations, which involves driving the pressing member in the pressing direction by means of the toggle-mechanism, and thereby forming the non-flat cellulose product from the air- formed
  • a method for forming non-flat cellulose products from an air-formed cellulose blank structure in a product forming unit that comprises a blank dry-forming module with a moveable forming wire, a toggle pressing module with a toggle press and a forming mould, and an electronic control system operatively connected to the forming wire and the toggle pressing module.
  • the toggle press includes a pressing member movably arranged in a pressing direction, a toggle-mechanism drivingly connected to the pressing member, a pressing actuator arrangement drivingly connected to the toggle- mechanism.
  • the forming mould includes a moveable first mould part attached to the pressing member and a second mould part.
  • the method comprises: air-forming a cellulose blank structure onto the forming wire by means of the blank dry-forming module; feeding the air-formed cellulose blank structure into a pressing area defined by the first and second, spaced apart, mould parts; controlling operation of the pressing actuator arrangement by means of the electronic control system for performing pressing operations, which involves driving the pressing member in the pressing direction by means of the toggle-mechanism, and thereby forming the non flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part against the second mould part; and controlling operation of the forming wire by means of the electronic control system for intermittently feeding the forming wire between subsequent pressing operations.
  • Toggle mechanism clamps are well known in the field of injection moulding, where for example a plastic material in a liquid phase is injected with high pressure into a cavity formed by a closed mould.
  • the purpose of the toggle mechanism clamp is merely to close the injection mould parts and to exert a sufficient clamping force to avoid separation of the mould parts due to internal injection pressure within the mould.
  • toggle mechanism is less commonly used for compression moulding applications, in which the pressure level typically is a relevant parameter that may have to be controlled with a certain accuracy, partly because control of pressing force is more complicated due to the exponential amplification character of the toggle mechanism, and partly because the resulting pressing force cannot be easily determined with good accuracy.
  • the pressing force generated by a pressing actuator arrangement on the toggle mechanism approaches zero when the toggle mechanism approaches the force equilibrium position, thereby rendering the pressing force of the pressing actuator arrangement less useful for determining pressing force.
  • toggle presses have, compared with conventional high capacity hydraulic or servo presses, the advantage of being relatively compact and low-cost due to the low input pressing force requirement.
  • a relatively small capacity actuator such as a small capacity hydraulic or pneumatic linear actuator, i.e. cylinder-piston arrangement, or low power electric motor driven ball-screw linear actuator, may be sufficient for driving the toggle mechanism and thereby generating a significantly larger pressing force.
  • the toggle press also has an inherent highly beneficial speed-force characteristic that enables significant reduction in cycle time of the cellulose product forming cycle, compared with conventional high capacity hydraulic or servo presses.
  • the inherent force amplification characteristic of the toggle mechanism results in a relatively fast speed of the pressing member during an initial cycle time, starting from the standby position, while the speed is gradually reduced when approaching the maximal stroke state of the toggle mechanism in benefit for increased maximal pressing force.
  • the initial motion of the pressing member is associated with high speed and low maximal pressing force
  • motion of the pressing member during the actual pressing action is associated with low speed and high maximal pressing force.
  • the electronic control system configured for intermittently feeding the forming wire between subsequent pressing operations, the need for a relatively large, complex and costly buffer apparatus arranged in the region between the blank dry-forming module and pressing module is eliminated, thereby further assisting in reducing overall cost of the product forming unit.
  • the compact size and low weight of the toggle press enables development of a very compact, complete, fully integrated, standardized cellulose product forming unit, that may be easily shipped, installed and made to run, and the low cost for a toggle press helps keeping the total cost for the cellulose product forming unit at a low level.
  • said pressing operations involves driving the pressing member in the pressing direction by setting the toggle-mechanism a maximal extended operating position, i.e. aligned first and second link members of the toggle-mechanism.
  • a maximal extended operating position i.e. aligned first and second link members of the toggle-mechanism.
  • This enables simplified control of the actuator arrangement used for driving the toggle-mechanism, because the control may be performed using for example position of the pressing member, or similarly easily detectable parameter, as feedback signal.
  • the target pressing force is relatively easily and robustly accomplished, compared with working for example near the asymptotic operating region associated with the non-aligned link member operating region of the toggle press.
  • the toggle press is installed, or arranged for being installed, with the pressing direction of the pressing member arranged primarily in a horizontal direction, specifically with the pressing direction of the pressing member arranged within 20 degrees from the horizontal direction, and more specifically with the pressing direction in parallel with the horizontal direction.
  • the primarily horizontal orientation of the toggle press enables low build height of the cellulose product forming unit, and a non-straight material flow of a continuous air-formed cellulose blank structure from a blank dry-forming module to the pressing module.
  • a non straight material flow e.g.
  • a continuous air-formed cellulose blank structure in a first direction, such as for example upwards and subsequently in a second direction, such as for example downwards, generally enables development and manufacturing of a more compact cellulose product forming unit. Since a web of cellulose fibre material is typically supplied to the pressing module at about right angles to the pressing direction of the pressing module, a primarily horizontal orientation of the toggle press is typically associated with a primarily vertically arranged supply flow of the cellulose blank structure Consequently, it is clear that a primarily horizontally arranged pressing module is highly beneficial when developing a compact cellulose product forming unit having a non-straight material flow of an air- formed cellulose blank structure from a blank dry-forming module to the pressing module.
  • the electronic control system is configured for intermittently feeding the forming wire between subsequent pressing operations, such that the forming wire is operated periodically with a relatively high speed during time periods between subsequent pressing operations, and with a relatively low speed, or zero speed, during time periods coinciding with pressing operations.
  • the electronic control system is configured for synchronized operation of the forming wire and the toggle press, such that the forming wire is operated, or operated with a relatively high speed, during time periods when the toggle press is a non-pressing state, and such that the forming wire is in stillstand state, or operating with a relatively low speed, during time periods when the toggle press is a pressing state.
  • the electronic control system is configured for controlling operation of forming wire and the toggle press, such that the feeding speed of the forming wire, in particular over a complete pressing cycle, is equal to, or at least substantially equal to, the feeding speed of the air-formed cellulose blank structure entering the forming mould.
  • the product forming unit is free from a buffering module arranged between the blank dry-forming module and the toggle pressing module.
  • the omission of the buffering module results in a more cost-efficient product forming unit.
  • the toggle press further includes: a pressing force indicating arrangement; an adjustment mechanism for enabling adjustment of a distance between the first and second mould parts in the pressing direction while having the toggle-mechanism in a non-moving operating state; and an adjustment actuator arrangement configured for driving the adjustment mechanism, wherein the electronic control system is operatively connected to the pressing force indicating arrangement and configured to control operation of the adjustment actuator arrangement, based on pressing force indicating feedback information received from the pressing force indicating arrangement.
  • the operating position of the toggle press may be adjusted to better fit and/or adapt to the specific characteristic of the cellulose blank structure and forming mould shape.
  • the electronic control system is configured to control operation of the adjustment actuator arrangement for adjusting the distance between the first and second mould parts during a time period between consecutive pressing actions, such that the pressing member during the next pressing cycle is targeted to provide a compression force closer to a predetermined target pressing force.
  • the operating position of the toggle press may be adjusted to better fit and/or adapt to the specific characteristic of the cellulose blank structure and forming mould shape.
  • the pressing force indicating arrangement includes one or more of the following sensors: a load cell, a deformation sensor, or a strain gauge force sensor, and wherein said one or more sensors is located at or within the forming mould, or on the toggle-mechanism, or between the toggle mechanism and a rear structure of a rigid frame structure of the toggle press, or between the toggle- mechanism and the forming mould, or at the rigid frame structure of the toggle press, or at a tie bar of an intermediate linear guiding arrangement of the toggle press.
  • the toggle press further includes a front structure and a rear structure, wherein the toggle-mechanism is connected to the rear structure, wherein the second mould part is attached to the front structure, and wherein the mechanical adjustment mechanism enables adjustment of a distance between the front structure and rear structure, in the pressing direction, for enabling adjustment of a distance between the first and second mould parts while having the toggle- mechanism in a non-moving operating state.
  • each of the first and second mould parts comprises a main rigid plate-shaped body with a surface configured for facing the other mould part, and at least one pressing surface defining one or more forming cavities for forming a cellulose product, and with or without additional minor parts, such as spring- loaded cutting devices and/or mould alignment devices, or the like, wherein said surfaces of the main rigid plate-shaped body of the first and second mould forming parts are free from mutual direct contact during a pressing cycle.
  • the forming mould may be used for press forming of a non-flat cellulose product with a certain forming pressure without undesired interference between said surfaces.
  • the forming mould is configured for forming the cellulose products from the cellulose blank structure by heating the cellulose blank structure to a forming temperature in the range of 100-300 °C, and pressing the cellulose blank structure with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa. These parameters are providing an efficient forming of the cellulose products, where strong hydrogen bonds are formed.
  • the blank dry-forming module further comprises a mill and a forming chamber, wherein the forming wire is arranged in connection to the forming chamber, wherein the mill is configured for separating fibres from a cellulose raw material, wherein the forming chamber is configured for distributing the separated fibres onto a forming section of the forming wire for forming the cellulose blank structure.
  • the mill and forming chamber enables forming of the cellulose blank structure in close connection to the pressing module, without the need for pre fabricating the cellulose blank structure, such that a compact layout can be achieved, and operation of the product forming unit is efficient with the cellulose raw material used as input material for in-line production of the cellulose blank structure.
  • the forming section of the forming wire is extending in an upwards blank forming direction. This enables designing a more compact and shorter product forming unit, because the air-formed cellulose blank structure is at least initially routed upwards, and thus not only in the horizontal direction.
  • the blank dry-forming module is configured for air forming discrete cellulose blanks onto the forming wire, or wherein the blank dry forming module is configured for air-forming a continuous cellulose blank structure onto the forming wire.
  • Forming discrete cellulose blanks onto the forming wire may in certain implementations result in reduced level of residual material after forming, thereby reducing cost for raw material.
  • the pressing operation is a single pressing operation.
  • the product forming unit is adapted for intermittently feeding the cellulose blank structure from the blank dry-forming module by the forming wire in a first feeding direction, and for intermittently feeding the cellulose blank structure to the pressing module in a second feeding direction, wherein the second feeding direction differs from the first feeding direction, specifically wherein the second feeding direction is opposite to, or essentially opposite to, the first feeding direction.
  • the differing feeding directions enable the modules to be integrated into one single unit or machinery possible to ship in a freight container, place on a converter ' s plant floor, connect and start production in a few months with no or very little module engineering skill required from the converter.
  • the differing feeding directions enable a more compact layout and construction of the product forming unit.
  • the modules can be positioned in relation to each other in a non-conventional manner for an efficient and compact layout.
  • the integrated module design enables the weight of the production forming unit to be several times less than today’s units with aligned discrete separately purchased modules into a custom-made industrial line.
  • the weight of machinery commonly relates to the purchase price, why this solution also lowers the investment costs with several times for the converter.
  • the lower investment costs enable a faster conversion to products made of cellulose raw materials instead of plastic materials.
  • the first feeding direction is an upwards direction and the second feeding direction is a downwards direction. This enables a smart and efficient layout of the product forming unit, where the unit can be built in a vertical direction for a compact layout.
  • the product forming unit further comprises a cellulose blank transport device, in particular a conveyer belt and/or a set of feeding rollers, configured for transporting the air-formed cellulose blank structure from forming wire of the blank dry-forming module to the forming mould of the toggle pressing module, wherein the electronic control system is configured for providing substantially synchronized operation of the forming wire and transport device.
  • a cellulose blank transport device in particular a conveyer belt and/or a set of feeding rollers, configured for transporting the air-formed cellulose blank structure from forming wire of the blank dry-forming module to the forming mould of the toggle pressing module
  • the electronic control system is configured for providing substantially synchronized operation of the forming wire and transport device.
  • the electronic control system is configured continuously operating the mill; and continuously feeding the cellulose raw material to the mill, or intermittently feeding the cellulose raw material to the mill.
  • the product forming unit further comprises a blank recycling module configured for transporting residual parts of the cellulose blank structure from the pressing module to the blank dry-forming module. The transportation of the residual parts is securing that non-used parts of the cellulose blank structure can be re-used.
  • the blank recycling module comprises a recycling compacting unit configured for compacting the residual parts of the cellulose blank structure in the recycling compacting unit upon transportation from the pressing module to the blank dry-forming module. By compacting the residual parts, an efficient operation in the mill is achieved.
  • the method comprises controlling operation of the forming wire by means of the electronic control system for intermittently feeding the forming wire between subsequent pressing operations, such that the forming wire is operated periodically with a relatively high speed during time periods between subsequent pressing operations, and with a relatively low speed, or zero speed, during time periods coinciding with pressing operations.
  • the method comprises controlling operation of the forming wire and the pressing actuator arrangement for synchronized operation of the forming wire and the toggle press, such that the forming wire is operated, or operated with a relatively high speed, during time periods when the toggle press is a non pressing state, and such that the forming wire is in stillstand state, or operating with a relatively low speed, during time periods when the toggle press is a pressing state.
  • the method comprises controlling operation of forming wire and the toggle press by means of the electronic control system, such that the feeding speed of the forming wire is equal to, or at least substantially equal to, the feeding speed of the air-formed cellulose blank structure entering the forming mould.
  • the method comprises controlling operation of the adjustment actuator arrangement for adjusting the distance between the first and second mould parts during a time period between consecutive pressing actions, such that the pressing member during the next pressing cycle is targeted to provide a compression force closer to a predetermined target pressing force.
  • the step of air-forming the cellulose blank structure from the cellulose raw material in the blank dry-forming module involves: separating fibres from the cellulose raw material in a mill and distributing the separated fibres onto a forming wire of the blank dry-forming module for forming the cellulose blank structure, and transporting the formed cellulose blank structure in the upwards blank forming direction.
  • the non-conventional upwards extension of the forming section is enabling a compact layout of the product forming unit, since the cellulose blank structure can be formed in an upwards direction and subsequently re-directed for transportation to the pressing module.
  • the cellulose blank structure is air-formed in the dry forming module into a discrete cellulose blank, or wherein the cellulose blank structure is air-formed in the dry-forming module into a continuous cellulose blank.
  • the cellulose blank structure is intermittently transported from the blank dry-forming module by the forming wire in a first feeding direction, and intermittently transported to the pressing module in a second feeding direction, wherein the second feeding direction differs from the first feeding direction, specifically wherein the second feeding direction is opposite to, or essentially opposite to, the first feeding direction.
  • the method further comprises the steps: continuously operating the mill; and continuously feeding the cellulose raw material to the mill, or intermittently feeding the cellulose raw material to the mill.
  • the composition of the resulting air-laid the cellulose blank structure may be altered and adapted according to the specific circumstances.
  • the forming wire comprises a forming section arranged in connection to a forming chamber opening of the forming chamber, wherein the method further comprises the step: air-forming the cellulose blank structure onto the forming section.
  • the forming section is controlling the forming of the cellulose blank structure onto the forming wire, and the forming section may be used for shaping the cellulose blank structure into suitable configurations.
  • the product forming unit comprises a blank recycling module, wherein the method further comprises the step: transporting residual parts of the cellulose blank structure from the pressing module to the blank dry-forming module.
  • the blank recycling module comprises a recycling compacting unit
  • the method further comprises the step: compacting the residual parts of the cellulose blank structure in the recycling compacting unit upon transportation from the pressing module to the blank dry-forming module.
  • the present disclosure also relates to a cellulose product toggle pressing module for forming non-flat cellulose products from an air-formed cellulose blank structure.
  • the toggle pressing module comprising: a toggle press including a pressing member movably arranged in a pressing direction, a toggle-mechanism drivingly connected to the pressing member, a pressing actuator arrangement drivingly connected to the toggle-mechanism for controlling motion of the toggle-mechanism between a retracted operating position and an extended operating position; a forming mould including a moveable first mould part attached to the pressing member and a second mould part; an adjustment mechanism for enabling adjustment of a distance between the first and second mould parts in the pressing direction while having the toggle- mechanism in a non-moving operating state, and an adjustment actuator arrangement configured for driving the adjustment mechanism; a pressing force indicating arrangement; and an electronic control system operatively connected to the pressing force indicating arrangement, the pressing actuator arrangement and the adjustment actuator arrangement; wherein the electronic control system is configured for controlling operation of pressing actuator arrangement for driving the pressing member in the pressing direction by setting the
  • the present disclosure also relates to a method for forming non-flat cellulose products from an air-formed cellulose blank structure in a toggle pressing module, which comprises: a toggle press including a pressing member movably arranged in a pressing direction, a toggle-mechanism drivingly connected to the pressing member, a pressing actuator arrangement drivingly connected to the toggle-mechanism for controlling motion of the toggle-mechanism between a retracted operating position and an extended operating position; a forming mould including a moveable first mould part attached to the pressing member and a second mould part; an adjustment mechanism for enabling adjustment of a distance between the first and second mould parts in the pressing direction while having the toggle-mechanism in a non-moving operating state, and an adjustment actuator arrangement configured for driving the adjustment mechanism; a pressing force indicating arrangement; and an electronic control system operatively connected to the pressing force indicating arrangement, the pressing actuator arrangement and the adjustment actuator arrangement.
  • the method comprises: air-forming a cellulose blank structure onto the forming wire by means of the blank dry-forming module; feeding the air-formed cellulose blank structure into a pressing area defined by the first and second, spaced apart, mould parts; controlling operation of the pressing actuator arrangement for performing pressing operations, which involves driving the pressing member in the pressing direction by setting the toggle-mechanism in the extended operating position, and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part against the second mould part; and controlling operation of the adjustment actuator arrangement, based on pressing force indicating feedback information received from the pressing force indicating arrangement.
  • Fig. 1a shows a schematic layout of the product forming unit according to the disclosure
  • Fig. 1b shows schematically a perspective view of a product forming unit according to the disclosure
  • Fig. 1c shows schematically, in a perspective view, a blank dry-forming module according to the disclosure
  • Fig. 1d-e show schematically two example embodiments of the routing of the cellulose blank structure within the product forming unit according to the disclosure
  • Fig.2a-b show two timing diagrams reflecting alternative control strategies for operating the product forming unit according to the disclosure
  • Fig.3a shows schematically a perspective view of the pressing module according to the disclosure
  • Fig. 3b-e show schematically side views of the cellulose forming process within the forming mould according to the disclosure
  • Fig. 4a-b show schematically side views of the pressing module according to the disclosure
  • Fig. 5 shows the main process steps of a pressing cycle
  • Fig. 6a-b show schematically side views of alternative orientations of the pressing module according to the disclosure
  • Fig. 7a-b show schematically side views of alternative designs of the toggle mechanism according to the disclosure
  • Fig. 8a-c show schematically side views of alternative operative settings of the adjustment mechanism of the pressing module according to the disclosure
  • Fig. 9 shows a pressing force curve
  • Fig. 10a-b show schematically alternative control systems of the pressing module according to the disclosure
  • Fig. 11 shows an alternative schematic layout of the product forming unit according to the disclosure
  • Fig. 12a-b show schematically side views of the pressing module according to a further example embodiment of the disclosure
  • Fig. 13-14 show schematically some basic steps of various methods according to the disclosure.
  • Figures 1a and 1b schematically show different schematic views of an example embodiment of a product forming unit U for manufacturing cellulose products 1 from an air-formed cellulose blank structure 2.
  • Figure 1a shows a schematic layout of the product forming unit U and figure 1b shows a perspective side-view of the product forming unit U.
  • the product forming unit U has extensions in a horizontal direction or plane D H and a vertical direction Dv.
  • the product forming unit U comprises a blank dry-forming module 4 and a pressing module 6, as will be further described below.
  • the cellulose products 1 are formed from the cellulose blank structure 2 in the product forming unit U.
  • the pressing module 6 comprises one or more forming moulds 3 for forming the cellulose products 1 from the cellulose blank structure 2 in a pressing operation.
  • the cellulose blank structure 2 is air-formed in the blank dry-forming module 4 onto a forming wire 4c, and fed to the one or more forming moulds 3 of the pressing module 6.
  • the forming of the cellulose products 1 is thus accomplished in the pressing module 6.
  • the cellulose products 1 are non-flat. With non-flat products is meant products that have an extension in three dimensions, which is different from flat products like blanks or sheets.
  • an air-formed cellulose blank structure 2 is meant an essentially air-formed fibrous web structure produced from cellulose fibres.
  • the cellulose fibres may originate from a suitable cellulose raw material R, such as a pulp material. Suitable pulp materials are for example fluff pulp, paper structures, or other cellulose fibre containing structures.
  • air-forming of the cellulose blank structure 2 is meant the formation of a cellulose blank structure in a dry-forming process in which the cellulose fibres are air-formed to produce the cellulose blank structure 2.
  • the cellulose fibres are carried and formed to the fibre blank structure 2 by air as carrying medium. This is different from a normal papermaking process or a traditional wet-forming process, where water is used as carrying medium for the cellulose fibres when forming the paper or fibre structure.
  • the cellulose blank structure 2 may, if suitable have a dryness that is mainly corresponding to the ambient humidity in the atmosphere surrounding the air-formed cellulose blank structure 2.
  • the dryness of the cellulose blank structure 2 can be controlled in order to have a suitable dryness level when forming the cellulose products 1.
  • the blank dry-forming module 4 of the embodiment illustrated in figures 1a and 1b, which is shown separately in figure 1c, has a horizontal distribution direction of the cellulose fibres F from the mill 4a to the forming wire 4c through the forming chamber 4b.
  • a horizontal flow of air is thus feeding the cellulose fibres F from the mill 4a to the forming section 4d, which is different from traditional dry-forming systems with a vertical flow of air.
  • the length of the fibre carrying distance by the flow of air inside the forming chamber 4b needs to be long enough to minimize turbulence and/or create a uniform flow of cellulose fibres F.
  • the length of the blank forming module 4 is therefore dependent of the fibre carrying distance by the flow of air.
  • the upwards blank forming direction Du enables a compact configuration and layout of the product forming unit U, and is reducing the length of the product forming unit U compared to traditional solutions. Further, access for maintenance of the mill 4a from a plant floor level is enabled without additional elevated flooring structures or platforms, due to the positioning of the blank dry-forming unit 4 at the plant floor level. This positioning and the horizontal flow of air also enables low height of the product forming unit U compared to traditional solutions using vertical air flow.
  • the cellulose blank structure 2 may be air-formed in the dry-forming module 4 into discrete cellulose blanks.
  • the discrete cellulose blanks are formed as discrete pieces of material that are separated from each other and may for example be shaped into suitable configurations to avoid residual material after forming, which is minimizing the amount of cellulose material used.
  • the cellulose blank structure 2 may be air-formed in the dry-forming module 4 into a continuous cellulose blank 2b.
  • the basis weight of the air-formed cellulose blank structure 2 may be uniform or varying.
  • the blank dry-forming module 4 comprises a mill 4a, a forming chamber 4b, and a forming wire 4c arranged in connection to the forming chamber 4b. Fibres F from the cellulose raw material R is separated from the cellulose raw material R in the mill 4a and the separated fibres F are distributed into the forming chamber 4b onto the forming wire 4c for forming the cellulose blank structure 2.
  • the mill 4a is configured for separating cellulose fibres F from the cellulose raw material R
  • the forming chamber 4b is configured for distributing the separated fibres F onto a forming section 4d of the forming wire 4c for forming the cellulose blank structure 2.
  • the forming section 4d is arranged in connection to a forming chamber opening 4e of the forming chamber 4b.
  • the forming section 4d is extending in an upwards blank forming direction Du.
  • the cellulose blank structure 2 is formed onto the forming section 4d, and transported by the forming wire 4c from the forming section 4d in the upwards blank forming direction Du, and subsequently further towards the pressing module 6.
  • the upwards blank forming direction Du is used for a compact configuration and layout of the product forming unit U, allowing an efficient positioning of the different modules of the product forming unit U in relation to each other.
  • the pulp structure 20 used may for example be bales, sheets, or rolls of fluff pulp, paper structures, or other suitable cellulose fibre containing structures, that are fed into the mill 4a.
  • the mill 4a may be of any conventional type, such as for example a hammer mill, a saw-tooth mill, or other type of pulp de-fiberizing machine.
  • the pulp structure 20 is fed into the mill 4a through an inlet opening, and the separated fibres F are distributed to the forming chamber 4b through an outlet opening of the mill 4a arranged in connection to the forming chamber 4b.
  • the forming chamber 4b is arranged for distributing the separated fibres onto the forming wire 4c for air-forming the cellulose blank structure 2.
  • the forming chamber 4b is arranged as a hood structure or compartment in connection to the forming wire 4c.
  • the forming chamber 4b is enclosing a volume in which the separated fibres F are distributed from the mill 4a to the forming wire 4c.
  • the cellulose fibres F are distributed by a flow of air generated by the mill 4a, and the flow of air is transporting the fibres in the forming chamber 4b from the mill 4a to the forming wire 4c.
  • the forming wire 4c may be of any suitable conventional type, and may be formed as an endless belt structure, as illustrated in figures 1a-b.
  • a vacuum box 4f may be arranged in connection to the forming wire 4c and the forming chamber 4b for controlling the flow of air in the forming chamber 4b, and for distributing the separated fibres F onto the forming wire 4c.
  • the forming wire 4c has a first side S1 facing the forming chamber 4b and a second side S2 facing the vacuum box 4f.
  • the cellulose blank structure 2 is in this way air-formed onto the first side S1 of the forming wire 4c upon application of a negative pressure PNEG onto the second side S2 for securing attachment of the cellulose fibres F onto the first side S1.
  • the blank dry-forming module 4 is as illustrated in for example figures 1a-1c is arranged upstream the pressing module 6.
  • the pressing module 6 includes a toggle press 6a with a forming mould 3 mounted therein.
  • the toggle press 6a operates with a reciprocating motion having two main phase: an open phase during which the cellulose blank structure 2 may be fed into the forming mould, and a pressing phase during which the cellulose blank structure 2 within the forming mould is non-moving. Consequently, the cellulose blank structure 2 needs to be intermittently transported to the forming mould 3 of the pressing module 6.
  • Intermittent feeding of the cellulose blank structure 2 to the forming mould 3 of the pressing module 6 is, according to the present disclosure, is solved by operating also the forming wire 4a of the blank dry-forming module 4 intermittently and in a synchronized manner with pressing module 6.
  • the product forming unit U additionally includes an intermediate feeding device 16 arranged between the blank dry-forming module 4 and pressing module 6.
  • the intermediate transport or feeding device 16 which may be a conveyer belt and/or a set of feeding rollers or the like, may then also be arranged to operate intermittently and in a synchronized manner with pressing module 6.
  • the product forming unit U may further comprise a cellulose blank transport device 16, in particular a conveyer belt, a set of feeding rollers, vacuum belts, elongated tractor belt feeders, or the like, configured for transporting the air- formed cellulose blank structure 2 from forming wire 4c of the blank dry-forming module 4 to the forming mould 3 of the toggle pressing module 6, wherein the electronic control system 6h is configured for providing substantially synchronized operation of the forming wire 4c and transport device.
  • the forming wire 4c and transport device are substantially always operating with the same transport speed.
  • the intermittent transporting of the cellulose blank structure 2 to the pressing module 6 is in the example embodiment of figure 1 a arranged partly with the forming wire 4a and partly with a suitable feeding device 16 that is intermittently controlled to feed the cellulose blank structure 2 to the pressing module 6.
  • the pressing module 6 is operated to apply the forming pressure PF onto the cellulose blank structure 2, the cellulose blank structure 2 is in a non-moving state, or at least in a state of low operating speed.
  • the feeding of the cellulose blank structure 2 to the forming position between the one or more first mould parts 3a and the one or more second mould parts 3b is taking place when the mould parts are in an open state, thereby allowing the cellulose blank structure 2 to be securely positioned between the one or more first mould parts 3a and the one or more second mould parts 3b without any disturbing interaction from the mould parts.
  • the present disclosure relates to a product forming unit U for manufacturing non-flat cellulose products 1 from an air-formed cellulose blank structure 2, wherein the product forming unit U comprises a blank dry-forming module 4 with a moveable forming wire 4c, a toggle pressing module 6 with a toggle press 6a and a forming mould 3, and an electronic control system 6h operatively connected to the forming wire 4c and the toggle press 6a.
  • the blank dry-forming module 4 is configured for air-forming the cellulose blank structure 2 onto the forming wire 4c.
  • the toggle press 6a includes a pressing member 6d movably arranged in a pressing direction DP, a toggle-mechanism 6e drivingly connected to the pressing member 6d, and a pressing actuator arrangement 6f drivingly connected to the toggle- mechanism 6e.
  • the forming mould 3 includes a moveable first mould part 3a attached to the pressing member 6d and a second mould part 3b.
  • the electronic control system 6h is configured for controlling operation of the pressing actuator arrangement 6f for performing pressing operations, which involves driving the pressing member 6d in the pressing direction DP by means of the toggle-mechanism 6e, and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part 3a against the second mould part 3b.
  • the electronic control system 6h further is configured for intermittently feeding the forming wire 4c between subsequent pressing operations.
  • the moveable forming wire 4c is for example an air-permeable conveyer belt.
  • the air-formed cellulose blank structure 2 is for example an air-formed fibrous web structure produced from cellulose fibres.
  • the electronic control system 6h is operatively connected to a driving motor 5 of forming wire 4c and to a pressing actuator arrangement 6f of the toggle press 6a.
  • the electronic control system 6h is configured for controlling operation of the pressing actuator arrangement 6f for driving the pressing member 6d in a direction opposite to the pressing direction DP for opening the forming mould 3.
  • FIG 2a shows a timing diagram of short operating sequence of the product forming unit U, including the operating speed Vw of the forming wire 4c overtime (solid line), as well as the operating speed VP of the pressing member over time (dashed line).
  • the forming mould 3 is in the opened state, and the forming wire 4c is temporarily activated for feeding a new section of the cellulose blank structure 2 into the forming mould 3.
  • the operating speed Vw of the forming wire 4c goes from zero to a predetermined target speed V1 , and subsequently back to zero speed.
  • the cellulose blank structure 2 may here be deemed having the same feeding speed into the forming mould as the operating speed Vw of the forming wire 4c.
  • a second time period t2 which in the illustrated example embodiments follows the first time period t1 except for a small overlap with the ending of first time period t1 , the pressing member 6d is controlled to move forwards for closing to the forming mould 3, and to start a fibre forming event.
  • the operating speed VP of the pressing member 6d goes from zero to a predetermined target speed, and subsequently back to zero speed.
  • the operating speed Vw of the forming wire 4c is zero during at least the end region of the second time period t2 for avoiding supply of cellulose blank structure 2 towards a closed forming mould 3.
  • both the forming wire 4c and the pressing member 6d are controlled to temporarily hold the operating position, i.e. to remain in a non-moving state.
  • the forming mould 3 is closed and the toggle press 6a applies full compression force on the forming mould.
  • the third time period t3 corresponds to a fibre forming event of the cellulose blank structure 2 located in the forming mould 3.
  • a fourth time period t4 which follows the third time period t3, the pressing member 6d is controlled to move rearwards for opening the forming mould 3.
  • the operating speed VP of the pressing member 4c goes from zero to a predetermined target speed, and subsequently back to zero speed.
  • the return speed is here illustrated as being negative for indicating the motion direction of the pressing member 6d, namely retraction.
  • the operating speed Vw of the forming wire 4c goes from zero to a predetermined target speed again, thereby repeating the periodic sequence t5.
  • the total time period t5 composed of the accumulated time periods t1-t4 thus represent a repeating periodic operating sequence of the product forming unit U.
  • the timing diagram of figure 2a clearly shows the that electronic control system 6h is configured for intermittently feeding the forming wire 4c, because the operating speed Vw of the forming wire 4c is clearly not constant but rather periodically changing over a total time period t5.
  • timing diagram of figure 2a clearly shows the that electronic control system 6h is configured for feeding the forming wire 4c between subsequent pressing operations, i.e. before and after the third time period t3.
  • Figure 2a shows that the electronic control system 6h is configured for intermittently feeding the forming wire 4c between subsequent pressing operations, such that the forming wire 4c is operated periodically with a relatively high speed V1 during time periods t1 between subsequent pressing operations t3, and with zero speed during time periods t3 coinciding with pressing operations.
  • FIG 2b shows a timing diagram of short operating sequence of the product forming unit U, including the operating speed Vw of the forming wire 4c over time (solid line), as well as the operating speed VP of the pressing member over time (dashed line).
  • the operating sequence and operating speed VP of the pressing member 6d is substantially equal to that described above with reference to figure 2a.
  • this example embodiment shows that the forming wire 4c may be controlled to have a certain operating speed Vw during time periods t3 coinciding with pressing operations. This may in certain applications be deemed advantageous, for example because it provides a more smooth and less variations in thickness of the resulting cellulose blank structure 2.
  • such operating control of the forming wire 4c generally requires a certain level of buffering of the cellulose blank structure 2 during transportation from the blank dry-forming module 4 to the toggle pressing module 6.
  • the operating speed Vw of the forming wire 4c may be relatively low during said time periods t3 coinciding with pressing operations. In fact, the operating speed Vw of the forming wire 4c may even be partly zero and partly above zero during time periods t3 coinciding with pressing operations. Consequently, the buffering requirements may be held relative low, and implemented for example by means of a variable length hanging section of the cellulose blank structure 2, or variable length curved section of the cellulose blank structure 2, or some type of relatively small capacity buffering equipment.
  • the forming mould 3 is in the opened state, and the forming wire 4c is controlled for feeding a new section of the cellulose blank structure 2 into the forming mould 3.
  • the operating speed Vw of the forming wire 4c goes from a relatively low speed V2 to a predetermined, relatively high, target speed V1 , and subsequently back to relatively low speed V2.
  • the relatively low speed V2 may for example be about 1 - 30% of the relatively high speed V1.
  • a second time period t2 which in the illustrated example embodiments follows the first time period t1 except for a small overlap with the ending of first time period t1 , the pressing member 6d is controlled to move forwards for closing to the forming mould 3, and to start a fibre forming event.
  • the operating speed VP of the pressing member 6d goes from zero to a predetermined target speed, and subsequently back to zero speed.
  • the operating speed Vw of the forming wire 4c remains in this example embodiment at the relatively low speed V1. As soon as the forming mould 3 becomes closed the cellulose blank structure 2 starts accumulating in the buffer.
  • both the forming wire 4c and the pressing member 6d are controlled to temporarily hold the operating position, i.e. to remain in a non-moving state. This corresponds thus to fibre forming event of the cellulose blank structure 2 located in the forming mould 3.
  • a fourth time period t4 which follows the third time period t3, the pressing member 6d is controlled to move rearwards for opening the forming mould 3.
  • the operating speed VP of the pressing member 4c goes from zero to a predetermined target speed, and subsequently back to zero speed.
  • the return speed is here illustrated as being negative for indicating the motion direction of the pressing member 6d, namely retraction.
  • the cellulose blank structure 2 in the buffer may be supplied to the forming mould 3.
  • the timing diagram of figure 2b clearly shows the that electronic control system 6h may be configured for intermittently feeding the forming wire 4c, because the operating speed Vw of the forming wire 4c is clearly not constant but rather periodically changing over a total time period t5.
  • timing diagram of figure 2b clearly shows the that electronic control system 6h is configured for feeding the forming wire 4c between subsequent pressing operations, i.e. before and after the third time period t3.
  • figure 2b shows that the electronic control system 6h may be configured for intermittently feeding the forming wire 4c between subsequent pressing operations, such that the forming wire 4c is operated periodically with a relatively high speed V1 during time periods t1 between subsequent pressing operations t3, and with a relatively low speed, during time periods t3 coinciding with pressing operations.
  • the driving motor 5 of the forming wire 4c is operated to according to a periodic sequence, which includes a first time period of relatively high speed followed by a second time period of relatively low speed or zero speed.
  • the electronic control system 6h is configured for synchronized operation of the forming wire 4c and the toggle press 6a, such that the forming wire 4c is operated, or operated with a relatively high speed, during time periods when the toggle press 6a is a non-pressing state, and such that the forming wire 4c is in stillstand state, or operating with a relatively low speed V2, during time periods when the toggle press 6a is in a pressing state.
  • the electronic control system 6h may be configured for controlling operation of forming wire 4c and the toggle press 6a, such that the feeding speed of the forming wire, in particular over a complete pressing cycle t5, is equal to, or at least substantially equal to, the feeding speed of the air-formed cellulose blank structure 2 entering the forming mould 3.
  • the product forming unit U may be free from a buffering module arranged between the blank dry-forming module 4 and the toggle pressing module 6. This concerns in particular the product forming unit U described with reference to figure 2a.
  • the forming unit U may be arranged without any buffering modules or similar arrangements, or at least arranged with only relatively small buffering capacity, the intermittent transportation of the cellulose blank structure to the pressing module needs to be synchronized with the air-forming of the cellulose blank structure 2 in the blank dry-forming module 4.
  • a forming pressure may be applied to the cellulose blank structure 2 in only one pressing step during the pressing operation, as described above with reference to figures 2a-2b.
  • a forming pressure may be applied in two or more repeated pressing steps during the pressing operation, and in this way the mould parts are repeatedly exerting a forming pressure onto the cellulose blank structure.
  • the pressing operation is a single pressing operation, in which a forming pressure is applied to the cellulose blank structure 2 in only one pressing step during the pressing operation.
  • the single pressing operation is thus meant that the cellulose product 1 is formed from the cellulose blank structure 2 in one single pressing step in the pressing module 6.
  • the one or more first mould parts 3a and the one or more second mould parts 3b are interacting with each other for establishing a forming pressure and the forming temperature during a single operational engagement step.
  • a forming pressure and a forming temperature are not applied to the cellulose blank structure 2 in two or more repeated or subsequent pressing operations.
  • the product forming unit U therefore includes an electronic control system 6h arranged for controlling operation of both the a blank dry-forming module 4 and the toggle pressing module 6, and in particular for controlling operation of one or more driving motors used for driving the forming wire 4c of the a blank dry forming module 4, and for controlling operation of a pressing actuator arrangement 6f used for driving the toggle pressing module 6.
  • the mill 4a may be operated in different ways depending on the configuration of the cellulose blank structure 2 that is being air-formed in the blank dry-forming module 4.
  • the mill 4a is suitably continuously operated.
  • the cellulose raw material R is continuously fed to the mill 4a.
  • the cellulose raw material R is instead intermittently fed to the mill 4a.
  • the air-formed cellulose blank structure 2 may be formed of cellulose fibres in a conventional air-forming process or in a blank dry-forming module 4 as illustrated in figures 1a-b, and be configured in different ways.
  • the cellulose blank structure 2 may have a composition where the fibres are of the same origin or alternatively contain a mix of two or more types of cellulose fibres, depending on the desired properties of the cellulose products 1.
  • the cellulose fibres used in the cellulose blank structure 2 are during the forming process of the cellulose products 1 strongly bonded to each other with hydrogen bonds.
  • the cellulose fibres may be mixed with other substances or compounds to a certain amount as will be further described below. With cellulose fibres is meant any type of cellulose fibres, such as natural cellulose fibres or manufactured cellulose fibres.
  • the cellulose blank structure 2 may specifically comprise at least 95% cellulose fibres, or more specifically at least 99% cellulose fibres.
  • the air-formed cellulose blank structure 2 may have a single-layer or a multi-layer configuration.
  • a cellulose blank structure 2 having a single-layer configuration is referring to a structure that is formed of one layer containing cellulose fibres.
  • a cellulose blank structure 2 having a multi-layer configuration is referring to a structure that is formed of two or more layers comprising cellulose fibres, where the layers may have the same or different compositions or configurations.
  • the cellulose blank structure 2 may comprise a reinforcement layer comprising cellulose fibres, where the reinforcement layer may be arranged as a carrying layer for one or more other layers of the cellulose blank structure 2.
  • the reinforcement layer may have a higher tensile strength than other layers of the cellulose blank structure 2. This is useful when one or more air-formed layers of the cellulose blank structure 2 have compositions with low tensile strength in order to avoid that the cellulose blank structure 2 will break during the forming of the cellulose products 1.
  • the reinforcement layer with a higher tensile strength acts in this way as a supporting structure for other layers of the cellulose blank structure 2.
  • the reinforcement layer may be of a different composition than the rest of the cellulose blank structure, such as for example a tissue layer containing cellulose fibres, an airlaid structure comprising cellulose fibres, or other suitable layer structures. It is thus not necessary that the reinforcement layer is air-formed.
  • the cellulose blank structure 2 may comprise more than one reinforcement layer if suitable.
  • the cellulose blank structure 2 may further comprise or be arranged in connection to one or more barrier layers giving the cellulose products the ability to hold or withstand liquids, such as for example when the cellulose products 1 are used in contact with beverages, food, and other water-containing substances.
  • the one or more barrier layers may be of a different composition than the rest of the cellulose blank structure 2, such as for example a tissue barrier structure.
  • the one or more air-formed layers of the cellulose blank structure 2 are fluffy and airy structures, where the cellulose fibres forming the structures are arranged relatively loosely in relation to each other.
  • the fluffy cellulose blank structures 2 are used for an efficient forming of the cellulose products 1, allowing the cellulose fibres to form the cellulose products 1 in an efficient way during the forming process.
  • the product forming unit U may further comprise a barrier application module arranged upstream the pressing module 6.
  • the barrier application module is configured for applying a barrier composition onto the cellulose blank structure 2 before forming the cellulose products 1 in one or more forming moulds 3.
  • One preferred property of the cellulose products 1 is the ability to hold or withstand liquids, such as for example when the cellulose products are used in contact with beverages, food, and other water-containing substances.
  • the barrier composition may be one or more additives used when producing the cellulose products, such as for example AKD or latex, or other suitable barrier compositions.
  • Another suitable barrier composition is a combination of AKD and latex, where tests have shown that unique product properties may be achieved with a combination of AKD and latex added to the air-formed cellulose blank structure 2 when forming the cellulose products 1.
  • a high level of hydrophobicity can be achieved, resulting in cellulose products 1 with a high ability to withstand liquids, such as water, without negatively affecting the mechanical properties of the cellulose products 1.
  • the barrier application module may be arranged as a hood structure in connection to the cellulose blank structure 2, and the hood structure is comprising spray nozzles that are spraying the barrier composition continuously or intermittently onto the cellulose blank structure 2. In this way, the barrier composition is applied onto the cellulose blank structure 2 in the barrier application module.
  • the barrier composition may be applied on only one side of the cellulose blank structure or alternatively on both sides.
  • the barrier composition may further be applied over the whole surface or surfaces of the cellulose blank structure 2, or only on parts or zones of the surface or surfaces of the cellulose blank structure 2.
  • the hood structure of the barrier application module is preventing the barrier composition from being spread into the surrounding environment.
  • Other application technologies for applying the barrier structure may for example include slot coating and/or screen-printing.
  • the product forming unit U is further adapted for forming the non-flat cellulose products 1 from the cellulose blank structure 2 in the one or more forming moulds 3 by heating the cellulose blank structure 2 to the forming temperature T F , and pressing the cellulose blank structure 2 with the forming pressure.
  • the one or more forming moulds 3 are configured for forming the non-flat cellulose products 1 from the cellulose blank structure 2 by heating the cellulose blank structure 2 to the forming temperature T F in the range of 100-300 °C, and pressing the cellulose blank structure 2 with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa.
  • the differing first feeding direction DFI and second feeding direction DF2 are allowing a compact configuration and layout of the product forming unit U, and an efficient and compact positioning of the different modules of the product forming unit U in relation to each other.
  • the product forming unit is adapted for intermittently feeding the cellulose blank structure from the blank dry-forming module by the forming wire in a first feeding direction, and for intermittently feeding the cellulose blank structure to the pressing module in a second feeding direction, where the second feeding direction DF2 differs from the first feeding direction DFI .
  • the differing first feeding direction DFI and second feeding direction DF2 are allowing a compact configuration and layout of the product forming unit U, and an efficient and compact positioning of the different modules of the product forming unit U in relation to each other.
  • the second feeding direction DF2 is opposite to, or essentially opposite to, the first feeding direction DFI .
  • Having the second feeding direction DF2 arranged essentially opposite to the first feeding direction DFI means that the second feeding direction DF2 differs less than 45 degrees, specifically less than 30 degrees, from the opposite direction to the first feeding direction DFI .
  • the first feeding direction DFI is an upwards direction and the second feeding direction DF2 is a downwards direction, which is allowing a compact and efficient configuration of the product forming unit U.
  • the feeding route and feeding direction of the cellulose blank structure 2 of the example embodiment of figures 1a-b is for clarification purpose schematically illustrated in figure 1 d, and the compact configuration and layout of the product forming unit U enabled by routing the cellulose blank structure 2 first primarily upwards, then primarily horizontal and subsequently primarily downwards is clearly understandable, when compared with a conventional straight line horizontal routing of a cellulose product compression forming process.
  • the blank dry-forming module 4 may be arranged to have a primarily horizontal orientation of the feeding route and feeding direction of the cellulose blank structure 2, i.e. to have a primarily horizontal orientation of the forming wire 4c in the area of the forming chamber opening 4e, as schematically illustrated in figure 1e, before routing the cellulose blank structure 2 upwards, then primarily horizontal and subsequently primarily downwards to the pressing module 6.
  • This layout of the product forming unit U may also be used for providing a compact product forming unit U.
  • the blank dry-forming module 4 typically forms the start of the feeding route and the pressing module 6 typically forms the end of the feeding route, when not taking a blank recycling module 7 into account.
  • Other modules, such as the barrier application module are located at any suitable positions between the dry-forming module 4 and the pressing module 6, i.e. downstream of the dry-forming module 4 and upstream of the pressing module 6, and not necessarily at the example positions of the embodiment of figures 1 a-b.
  • the primarily downwards routing of the cellulose blank structure while passing the pressing module 6 is beneficial in terms of simplified feeding of the cellulose blank structure 2, as well as simplified cellulose products 1 plundering after completed forming process, i.e. upon leaving the pressing module 6.
  • high-speed intermittent feeding of the cellulose blank structure 2 from the dry-forming module 4 to the pressing module 6 may be difficult to accomplish with damaging or altering a characteristics of the cellulose blank structure 2, such as the thickness of the cellulose blank structure 2, or the like.
  • the toggle press in a primarily horizontal direction DH and feeding the cellulose blank structure primarily downwards to the pressing module 6, the gravitational force assist this feeding process, thereby requiring less force to be applied by a feeding device 16 for feeding the air-formed cellulose blank structure 2 into a pressing area 15 of the pressing module 6, and thereby reducing the risk for damages and/or altered characteristics of the cellulose blank structure 2.
  • plundering of the finished and ejected cellulose products 1 after completed forming process may also be simplified by means of the primarily vertical routing of the cellulose blank structure 2 through the forming mould 3, because the gravitational force may also here assist and simplify removal of the finished and ejected cellulose products 1 from the forming mould 3, and subsequent transportation to a storage chamber or conveyer belt, or the like.
  • the pressing module 6 comprises one or more forming moulds 3, as indicated in figures 1a-b and 3a, and each forming mould 3 comprises a first mould part 3a and a second mould part 3b. Corresponding first and second mould parts are cooperating with each other during the forming of the non-flat cellulose products 1 in the pressing module 6.
  • Each first mould part 3a and corresponding second mould part 3b are movably arranged in relation to each other, and the first mould part 3a and the second mould part 3b are configured for moving in relation to each other in a pressing direction Dp.
  • the second mould part 3b is stationary and the first mould part 3a is movably arranged in relation to the second mould part 3b in the pressing direction DP, and back.
  • the first mould part 3a is configured to move both towards the second mould part 3b and away from the second mould part 3b in linear movements along an axis extending in the pressing direction Dp.
  • first mould part 3a may be stationary with the second mould part 3b movably arranged in relation to the first mould part 3a, or both the first mould part 3a and the second mould part 3b may be movably arranged in relation to each other.
  • the pressing module 6 may be of a single-cavity configuration or alternatively of a multi-cavity configuration.
  • a single-cavity pressing module comprises only one forming mould 3 with first and second mould parts.
  • a multi-cavity pressing module comprises two or more forming moulds 3, each having cooperating first and second mould parts.
  • the pressing module 6 is arranged as a multi-cavity pressing module comprising a plurality of forming moulds 3 with first and second mould parts, where the movements of the mould parts suitably are synchronized for a simultaneous forming operation.
  • the part of the pressing module 6 shown in figures 3b-e is illustrating the single-cavity configuration, or alternatively a section of the multi-cavity configuration with one forming mould 3.
  • the pressing module 6 will be described in connection to a multi-cavity pressing module, but the disclosure is equally applicable on a single-cavity pressing module.
  • the expression moving in the pressing direction DP includes a movement in the pressing direction DP, and the movement may take place in opposite directions.
  • the expression may further include both linear and non-linear movements of a mould part, where the result of the movement during forming is a repositioning of the mould part in the pressing direction Dp.
  • the cellulose blank structure 2 is first provided from a suitable source.
  • the cellulose blank structure 2 may be air-formed from cellulose fibres and arranged on rolls or in stacks. The rolls or stacks may thereafter be arranged in connection to the forming mould system S.
  • the cellulose blank structure 2 may be air-formed from cellulose fibres in the blank dry-forming module 4 of the product forming unit U and directly fed to the pressing module 6.
  • the cellulose products 1 are formed from the cellulose blank structure 2 in the one or more forming moulds 3 by heating the cellulose blank structure 2 to a forming temperature TF in the range of 100-300 °C, and pressing the cellulose blank structure 2 with a forming pressure in the range of 1-100 MPa, preferably 4-20 MPa.
  • the first mould part 3a is arranged for forming the non-flat cellulose products 1 through interaction with the corresponding second mould parts 3b, as exemplified in figures 3b-e.
  • the cellulose blank structure 2 is in each forming mould 3 exerted to the forming pressure in the range of 1-100 MPa, preferably in the range of 4-20 MPa, and the forming temperature TF in the range of 100-300°C.
  • the cellulose products 1 are thus formed from the cellulose blank structure 2 between each of the first mould part 3a and corresponding second mould part 3b by heating the cellulose blank structure 2 to the forming temperature TF in the range of 100-300 °C, and by pressing the cellulose blank structure 2 with the forming pressure in the range of 1-100 MPa, preferably in the range of 4-20 MPa.
  • the pressing module 6 may further comprise a heating unit.
  • the heating unit is configured for applying the forming temperature TF onto the cellulose blank structure 2 in each forming mould 3.
  • the heating unit may have any suitable configuration.
  • the heating unit may be integrated in or cast into the first mould part 3a and/or the second mould part 3b, and suitable heating devices are e.g. electrical heaters, such as a resistor element, or fluid heaters. Other suitable heat sources may also be used.
  • the first mould part 3a is moved towards the second mould part 3b in the pressing direction DP, as illustrated with the arrow in figure 3c.
  • the cellulose blank structure 2 is being increasingly compacted between the pressing surface 3c, 3d of the mould parts, until the first mould part 3a have been further moved towards the second mould part 3b and reached a product forming position, as shown in figure 3d, in which the forming pressure and forming temperature TF is exerted onto the cellulose blank structure 2.
  • a forming cavity C for forming the cellulose products 1 is formed between each first mould part 3a and second mould part 3b during forming of the cellulose products 1 when each first mould part 3a is pressed towards its corresponding second mould part 3b with the cellulose blank structure 2 arranged between the mould parts.
  • the forming pressure and the forming temperature TF are applied to the cellulose blank structure 2 in each forming cavity C.
  • the forming of the cellulose products 1 may further include an edge-forming operation and a cutting or separation operation in the pressing module 6, where edges are formed on the cellulose products 1 and where the cellulose products 1 are separated from the cellulose blank structure 2 during forming of the cellulose products 1.
  • the mould parts may for example be arranged with edge-forming devices and cutting or separation devices for such operations, or alternatively the edges may be formed in the product cutting or separation operation.
  • a deformation element E for establishing the forming pressure may be arranged in connection to each first mould part 3a and/or second mould part 3b. In the embodiment illustrated in figures 3b-e, the deformation element E is attached to the first mould part 3a. By using a deformation element E, the forming pressure may be configured as an isostatic forming pressure.
  • the first mould part 3a and/or the second mould part 3b may comprise the deformation elements E, and the deformation elements E are configured for exerting the forming pressure on the cellulose blank structure 2 in the forming cavities C during forming of the cellulose products 1.
  • the deformation elements E may be attached to the first mould part 3a and/or the second mould part 3b with suitable attachment means, such as for example glue or mechanical fastening members.
  • suitable attachment means such as for example glue or mechanical fastening members.
  • the deformation elements E are made of a material that can be deformed when a force or pressure is applied, and the deformation elements E are suitably made of an elastic material capable of recovering size and shape after deformation.
  • the deformation elements E may further be made of a material with suitable properties that is withstanding the high forming pressure and forming temperature TF levels used when forming the cellulose products 1.
  • Certain elastic or deformable materials have fluid-like properties when being exposed to high pressure levels. If the deformation elements E are made of such a material, an even pressure distribution can be achieved in the forming process, where the pressure exerted on the cellulose blank structure 2 in the forming cavity C from the deformation elements E is equal or essentially equal in all directions between the mould parts. When each deformation element E under pressure is in its fluid-like state, a uniform fluid-like pressure distribution is achieved. The forming pressure is with such a material thus applied to the cellulose blank structure 2 from all directions, and the deformation element E is in this way during the forming of the cellulose products 1 exerting an isostatic forming pressure on the cellulose blank structure 2.
  • Each deformation element E may be made of a suitable structure of elastomeric material or materials, and as an example, the deformation element E may be made of a massive structure or an essentially massive structure of gel materials, silicone rubber, polyurethane, polychloroprene, or rubber with a hardness in the range 20-90 Shore A.
  • the product forming unit U comprises a blank recycling module 7 for recycling cellulose fibres.
  • the blank recycling module 7 is configured for feeding residual parts 2c of the cellulose blank structure 2 after forming of the cellulose products 1, from the pressing module 6 back to the blank dry-forming module 4.
  • the blank recycling module 7 is arranged for transporting residual cellulose blank fibre material from the pressing module 6 to the mill 4a.
  • the blank recycling module 7 the residual or remaining cellulose fibres can be recycled and re-used for forming a new cellulose blank structure 2 together with fibres from the cellulose raw material.
  • the blank recycling module 7 comprises a feeding structure 7a, such as feeding belts, a conveyer structure, or other suitable means for transporting the residual parts 2c from the forming moulds 3 to the mill 4a.
  • the mill 4a may be arranged with a separate inlet opening for the residual material, where the residual parts 2c of the cellulose blank structure 2 are fed into the mill 4a.
  • the blank recycling module 7 may comprise a recycling compacting unit 7b.
  • the recycling compacting unit 7b is compacting the residual parts 2c of the cellulose blank structure 2 upon transportation from the pressing module 6 to the blank dry-forming module 4.
  • the recycling compacting unit 7b is arranged as a pair of cooperating rollers that are compacting the residual parts 2c of the cellulose blank structure 2, as shown in figure 1a.
  • the blank recycling module 7 may instead comprise a channel structure with an inlet portion arranged in connection to the forming moulds 3, and the residual parts 2c of the cellulose blank structure can be sucked into the inlet portion for further transportation to the mill 4a.
  • the channel structure may further be arranged with a suitable combined mill and fan unit, which is used for at least partly separate the residual material before further transportation to an outlet portion in connection to the mill 4a.
  • the blank recycling module 7 may further comprise a buffering arrangement 51 that has the purpose of converting the intermittent feeding motion of the residual parts 2c exiting the pressing module 6a to continuous feeding motion before supplying the residual parts 2c to the mill 4a. This is particularly relevant when the residual parts 2c has the form a continuous web structure. Continuous feeding of residual parts 2c to the mill 4a may be advantageous in terms of a more equal supply rate of residual parts 2c, and thus formation of a more equally thick cellulose blank structure 2 in the forming wire 4c. However, due to the intermittent operation of the pressing module 6, the intermittent supply of residual parts 2c from the pressing module 6a need to be converted to continuous feeding without breaking the web structure of the residual parts 2c. To achieve this, the buffering arrangement 51 may comprise a residual parts 2c feeding system configured for intermittently feeding the residual parts 2c to the buffering arrangement 51 , and continuously feeding the residual parts 2c from the buffering module 5.
  • the buffering arrangement 5 may be implemented in form of hanging section of the continuous structure forming the residual parts 2c.
  • the residual parts 2c lacks vertical support from a conveyer belt, or the like, and may thus hang freely, wherein the buffering effect is accomplished by letting the residual parts 2c hang more or less deep in the hanging section.
  • the buffering arrangement 5 may alternatively be implemented in form of a mechanical device having one or more moving parts controlled by an actuator.
  • the modules described above a compact construction of the product forming unit U is enabled, and the modules may be integrated into one single product forming unit U that is possible to ship in a freight container, and placed on a converter ' s plant floor in a simple manner.
  • the differing feeding directions enable a more compact layout and construction of the product forming unit U.
  • the pressing module 6 is particularly suitable for forming non flat cellulose products 1 from an air-formed continuous cellulose blank structure 2, because a continuous cellulose blank structure 2 enables simplified handling and feeding of the blank structure 2 to the toggle press 6a, as well as simplified feeding of residual parts 2c of the cellulose blank structure 2 to the blank recycling module 7.
  • the cellulose product toggle pressing module 6 is also suitable for forming non-flat cellulose products 1 from an air-formed non-continuous cellulose blank structure 2, such as individual sheet pieces of air-formed cellulose blank structures 2.
  • the pressing actuator arrangement 6f may for example include a single or a plurality of hydraulic or pneumatic linear actuators, such as cylinder-piston actuators.
  • a motor with a rotating output shaft such as an electric, hydraulic or pneumatic motor may be used for driving a mechanical actuator, in particular a linear mechanical actuator, such as a ball screw, threaded rod actuator, rack and pinion actuator, etc.
  • the pressing actuator arrangement 6f may include a high-torque electric motor that is drivingly connected to the toggle- mechanism 6e via a rotary-to-linear transmission device, such as an eccentric mechanism or a crankshaft arrangement.
  • the pressing actuator arrangement 6f may include one or more high-torque electric motors that are integrally mounted in the toggle-mechanism 6e and directly drivingly connected with a rotating member or pivoting link of the toggle-mechanism 6e.
  • the moveable first mould part 3a may be directly or indirectly attached to the pressing member 6d. This means that there may for example be an intermediate member arranged between moveable first mould part 3a and the pressing member 6d, for example a load cell for detecting pressing force, or the like.
  • the stationary second mould part 3b is typically stationary during the pressing action but may nevertheless be adjustable in the pressing direction DP in the time period between consecutive pressing actions, as will be described more in detail below.
  • the toggle press 6a includes a front structure 6b and a rear structure 6c, wherein the toggle-mechanism 6e is connected also to the rear structure 6c, and wherein the stationary second mould part 3b is attached to the front structure 6b.
  • the stationary second mould part 3b may be directly or indirectly attached to the front structure 6b. This means that there may for example be an intermediate member arranged between stationary second mould part 3b and the front structure 6b, for example a load cell for detecting pressing force, or the like.
  • the front and rear structures 6b, 6c of the toggle press 6a represent two rigid and structurally relevant parts that must be interconnected by some kind of structurally rigid construction for ensuring that the front and rear structures 6a, 6c do not separate from each other during pressing action.
  • the front and rear structures 6b, 6c may have many different forms, depending on the specific circumstance.
  • the front and rear structures 6b, 6c may have a plate-like shape, in particular rectangular plate like shape, thereby enabling cost-effective manufacturing and the possibility of using the corner regions of the plate-shaped front and rear structures 6b, 6c for attachment to a common rigid frame structure.
  • the toggle press 6a typically comprises a rigid frame structure defined by the front structure 6b, the rear structure 6c and an intermediate frame structure that connects the front structure 6b with the rear structure 6c.
  • the toggle press 6a comprises a rigid frame structure defined by the front structure 6b, the rear structure 6c and an intermediate linear guiding arrangement 14 that connects the front structure 6b with the rear structure 6c, wherein the pressing member 6d is movably attached to the linear guiding arrangement 14 and moveable in the pressing direction Dp.
  • the rigid frame structure may be position on an underlying support frame 38 for providing the desired height and angular inclination of the toggle pressing module 6.
  • the intermediate frame structure may be provided by an intermediate linear guiding arrangement 14 that has a dual functionality in terms of providing structural strength and rigidity to the toggle press 6a, providing a rigid connection between the front and rear structure 6b, 6c, and additionally providing an intermediate linear guiding arrangement 14 for guiding of the pressing member 6d.
  • the intermediate linear guiding arrangement 14 may comprises four tie bars 37, of which one is arranged in each corner region of the plate-shaped front and rear structure 6b, 6c.
  • the tie bars are for example cylindrical and corresponding cylindrical holes may be provided in the corner regions of the plate-shaped front and rear structure 6b, 6c for receiving said tie bars.
  • the pressing member 6d may have any structural shape. However, in some example embodiments, also the pressing member has at least partly a plate-like shape, in particular a rectangular plate-like shape, thereby enabling cost-effective manufacturing and the possibility of using the corner regions of the plate-shaped pressing member 6d for attachment to the intermediate linear guiding arrangement 14.
  • the toggle press 6a may in some example embodiments be referred to as a three platen press.
  • the toggle press 6a is installed, or arranged for being installed, with the pressing direction of the pressing member 6d arranged or oriented primarily in a horizontal direction DH. Having the pressing direction arranged primarily in a horizontal direction DH means herein that that pressing direction is arranged closer to the horizontal direction than the vertical direction, i.e. below 45 degrees. Specifically, the toggle press 6a may be installed, or arranged for being installed, with the pressing direction of the pressing member 6d arranged within 20 degrees from the horizontal direction, and more specifically with the pressing direction parallel with the horizontal direction.
  • the toggle press 6a is for example installed with the pressing direction DP of the pressing member 6d arranged in the horizontal direction, as illustrated in figures 1a- b, 3a and 4a-b.
  • the beneficial aspects of enabling a compact overall design of the cellulose product forming unit U, with a low build-height is also obtainable when the toggle press 6a is installed in a slightly inclined state, depending on the circumstances. Consequently, the beneficial aspects of the cellulose product toggle pressing module 6 may be deemed obtainable with the toggle press 6a arranged with the pressing direction DP of the pressing member 6d arranged primarily in a horizontal direction DH, i.e.
  • the toggle press 6a may be installed with the pressing direction DP of the pressing member 6d arranged with an installation angle 13 in the range of 0-44 degrees, in particular in the range of 0-20 degrees, wherein said installation angle is defined by the pressing direction DP and the horizontal direction D h .
  • the beneficial aspect of enabling a compact overall design of the cellulose product forming unit U, and a low build-height is obtainable both when the rear structure 6c of the toggle press 6a is located higher up than the front structure 6b of the toggle press, as illustrated in figure 6a, and when the front structure 6b of the toggle press 6a is located higher up than the rear structure 6c of the toggle press, as illustrated in figure 6b.
  • a power source 39 for the pressing actuator arrangement 6f is illustrated installed under the support frame 38
  • a product plundering arrangement 48 is illustrated installed under the support frame 38.
  • the toggle press 6a further includes a feeding device 16 for providing intermittent feeding of the air-formed cellulose blank structure 2 into a pressing area 15 located between the first and second mould parts 3a, 3b, wherein the feeding device 16 is arranged for feeding the air-formed cellulose blank structure 2 primarily vertically downwards into the pressing area 15, specifically for feeding the air-formed cellulose blank structure 2 downwards with a feeding angle 49 of less than 20 degrees from a vertical direction into the pressing area 15, and more specifically for feeding the air-formed cellulose blank structure vertically downwards into the pressing area 15.
  • a feeding device 16 for providing intermittent feeding of the air-formed cellulose blank structure 2 into a pressing area 15 located between the first and second mould parts 3a, 3b, wherein the feeding device 16 is arranged for feeding the air-formed cellulose blank structure 2 primarily vertically downwards into the pressing area 15, specifically for feeding the air-formed cellulose blank structure 2 downwards with a feeding angle 49 of less than 20 degrees from a vertical direction into the pressing area 15, and more specifically for feeding the air-formed cellulose blank structure
  • the term primarily vertically here means feeding the blank structure in a direction that is arranged more vertical than horizontal.
  • a linear part of the feeding device 16 is oriented for defining an angle 49 with a vertical direction in the range of 0-44 degrees, in particular 0-20 degrees. Consequently, the feeding device 16 may be deemed being located primarily above the forming mould 3.
  • the interior flat side surfaces of the first and second mould parts 3a-b refers to those surfaces of the first and second mould parts 3a-b that face each other and surround the pressing surfaces of the pressing cavity.
  • the feeding device 16 for feeding the air- formed cellulose blank structure 2 into the pressing area 15 may include a motorized feeding roller or motorized pair of feeding rollers, or an elongated vacuum belt feeder or an elongated tractor belt feeder or the like, and with an intended feeding direction arranged primarily in a vertical direction Dv, specifically arranged with a direction of elongation 17 within 20 degrees from the vertical direction Dv, and more specifically arranged in parallel with the vertical direction Dv.
  • the toggle-mechanism 6e of the toggle press 6a may have a large variety of designs and implementations.
  • the basic requirement of the toggle-mechanism 6e is to generate a pressing force amplification, thereby enabling the use of a relatively low- cost and low-capacity pressing actuator arrangement 6f in term of pressing force.
  • the pressing force amplification is accomplished by a corresponding reduction of pressing speed of the pressing module.
  • the toggle-mechanism 6e amplifies and slows down a pressing force/speed compared with the force/speed of the pressing actuator arrangement 6f.
  • the toggle-mechanism 6e includes a first link member 18 and a second link member 19, wherein the pressing actuator arrangement 6f is directly or indirectly drivingly connected to the first or second link member 18, 19, such that actuation of the pressing actuator arrangement 6f results in motion of the pressing member 6d.
  • the toggle-mechanism 6e may in some example embodiments include a first link member 18 and a second link member 19, each having first and second pivot connections 18a, 18b, 19a, 19b, wherein the first pivot connection 18a of the first link member 18 is pivotally connected to the rear structure 6c, wherein the first pivot connection 19a of the second link member 19 is pivotally connected to the pressing member 6d, wherein the second pivot connection 18b of the first link member 18 is pivotally connected to the second pivot connection 19b of the second link member 19, and wherein the pressing actuator arrangement 6f is directly or indirectly drivingly connected to the first or second link member 18, 19 for adjusting a level of alignment between the first and second link members 18, 19, such that actuation of the pressing actuator arrangement 5f results in motion of the pressing member 6d.
  • the fact that the second pivot connection 18b of the first link member 18 is pivotally connected to the second pivot connection 19b of the second link member 19 means that the second pivot connection 18b of the first link member 18 is the same as the second pivot connection 19b of the second pivot
  • FIG 4a-b The effect of adjusting a level of alignment between the first and second link members 18, 19 is illustrated in figure 4a-b.
  • the alignment between the first and second link members 18, 19 is determined by an alignment angle 22 defined by longitudinal directions of the first and second link members 18, 19, as seen in a side-view according to figure 4a and 4b, wherein the longitudinal direction 18d of the first link member 18 is defined by a straight line passing the first and second pivot connections 18a, 18b of the first link member, and the longitudinal direction 19d of the second link member 19 is defined by a straight line passing the first and second pivot connections 19a, 19b of the second link member 19.
  • the alignment angle 22 is 180 degrees, which corresponds to alignment of the first link member 18 with the second link member 19.
  • This actuating position of the toggle-mechanism 6e may be referred to as a force equilibrium position.
  • the force equilibrium position is a position in which all forces are in balanced condition and the effect of forces cancel each other. In other words, in the force equilibrium position the force required by the pressing actuator arrangement 6f is equal to zero.
  • said pressing operations involves controlling the pressing actuator arrangement 6f for setting the toggle-mechanism 6e in said force equilibrium position.
  • the force equilibrium position corresponds to the maximal extended operating position of the toggle-mechanism 6e.
  • the toggle mechanism 6e illustrated in the example embodiment of figure 4a-b may be referred to as five-point double-toggle mechanism, meaning that there are two individual toggle mechanisms arranged side-by-side for providing a better force pressing force distribution to the pressing member 6d, and wherein each of said two individual toggle mechanisms include five pivot points.
  • the pressing actuator arrangement 6f is drivingly connected to a single cross head 20, and a cross head link member 21 has a first connection 21a that is pivotally connected to the cross head 20 and a second connection 21b that is pivotally connected to a third pivot connection 18c of the first link member 18.
  • the toggle mechanism 6e of the example embodiment of figures 4a-b comprises a single cross head that drives a first and second individual toggle mechanisms arranged side-by-side, each including a first link member 18, a second link member 19 and a cross head link member 21 , wherein the first link member 18 pivotally connected to a second link member 19 and to the rear structure 6c, wherein the second link member 19 is pivotally connected to the pressing member 6d, wherein the cross head link member 21 is pivotally connected to the first link member 18 and the cross head 20.
  • the cross head link member 21 may be pivotally connected to the second link member 19 and the cross head 20.
  • the second and third pivot connections 18b 18c of the first link member 18 may alternatively be a common pivot connection.
  • the toggle mechanism 6e may be three-point single-toggle mechanism as illustrated in figure 6a, wherein the toggle-mechanism 6e includes a first link member 18 pivotally connected to a second link member 19, wherein the first link member 18 is also pivotally connected rear structure 6c and the second link member 19 is pivotally connected to the front structure 6d, and a pressing actuator arrangement 6f is directly or indirectly drivingly connected to the first or second link member 18, 19, such that actuation of the pressing actuator arrangement 6f results in motion of the pressing member 6d.
  • toggle-mechanism 6e is schematically illustrated in figure 7a, which shows a three-point double-toggle mechanism, i.e. two three-point single-toggle mechanisms as described with reference to figures 6a, and with a pressing or pulling actuator arrangement 6f directly or indirectly drivingly connected to the first and/or second link member 18, 19 of both said single-toggle mechanisms.
  • an electric servo motor is depicted as actuator arrangement 6f.
  • the toggle-mechanism 6e as schematically illustrated in figure 7b includes a three-point double-toggle mechanism, i.e. two three-point single-toggle mechanisms as described with reference to figure 6a, but here operating in opposite directions and with an actuator arrangement 6f arranged between, and directly or indirectly drivingly connected to, the first and/or second link member 18, 19 of both said single-toggle mechanisms.
  • the toggle press 6a further includes: a pressing force indicating arrangement 6g, an adjustment mechanism 23 for enabling adjustment of a distance between the first and second mould parts 3a, 3b in the pressing direction while having the toggle- mechanism 6e in a non-moving operating state, and an adjustment actuator arrangement 25 configured for driving the adjustment mechanism 23, wherein the electronic control system 6h is operatively connected to the pressing force indicating arrangement 6g and configured to control operation of the adjustment actuator arrangement 25, based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g.
  • the mechanical adjustment mechanism 23 may comprise four gear wheels 26a-d, each having internal thread for threading mounting on a correspondingly threaded end portion of a tie bar of the linear guiding arrangement 14, and each 26a-d having external gear teeth for being driven by one or more motors of the adjustment actuator arrangement 25.
  • each of said four gears 26a-d of the mechanical adjustment mechanism 23 may be in contact with, and driven by, a single central gear wheel 27, which is powered by a single motor of the adjustment actuator arrangement 25.
  • Operation of the adjustment actuator arrangement 25 causes the mechanical adjustment mechanism 23 to alter the distance 24 between front and rear structure 6b, 6c, in the pressing direction, for enabling adjustment of a distance between the first and second mould parts 3a, 3b while having the toggle-mechanism 6e in a non- moving operating state.
  • This means that said adjustment of distance is not caused by movement of toggle-mechanism, but rather from the change of distance between the between front and rear structure 6b, 6c.
  • operation of the mechanical adjustment mechanism 23 displaces the rear structure 6c relative to the linear guiding arrangement 14 for altering the distance 24 between front and rear structure 6b, 6c.
  • operation of the mechanical adjustment mechanism 23 displaces the front structure 6b relative to the linear guiding arrangement 14 for altering the distance 24 between front and rear structure 6b, 6c.
  • the electronic control system 6h is typically configured to control operation of the adjustment actuator arrangement 25 for adjusting the distance between the first and second mould parts 3a, 3b during a time period between consecutive pressing actions, such that the pressing member 6d during the next pressing cycle is targeted to provide a compression force closer to a predetermined target pressing force.
  • FIG 5 schematically shows the main process steps of the pressing module 6 during normal operation.
  • the pressing operation flowchart typically starts with the pressing member in stillstand at a standby position S associated with retracted toggle mechanism and open pressing mould 3, as schematically illustrated in figure 4a.
  • the second step F of the flow chart is performed, which involves activating the pressing actuator arrangement 6f for pushing the pressing member 6d forwards F, until the forming mould 3 becomes closed and a forming pressure of about 1-100 Mpa, in particular 4- 20 Mpa, is applied to the cellulose blank structure in a third step P of the main process.
  • the fourth step R of the flow chart is performed, which involves initiating a return motion of the pressing member 6d towards the start position, i.e. the standby position S.
  • the process may skip step S, i.e. skip returning completely to the standby position S before initiating the second step F of the flow chart again.
  • maximal stroke state used herein also referred to as “maximal extended operating position” refers herein to the maximal forward position obtainable by the toggle mechanism when not being obstructed by the forming mould, the cellulose blank structure or other part, e.g. the aligned state of the first and second link members 18, 19 as shown in figure 4b.
  • each of the first and second mould parts 3a, 3b comprises a main rigid plate-shaped body with a typically substantially flat surface configured for facing the other mould part, and at least one pressing surface 3c, 3d defining one or more forming cavities C for forming a cellulose product 1, and with or without additional minor parts, such as spring-loaded cutting devices and/or mould alignment devices, or the like, wherein said substantially flat surfaces of the main rigid plate-shaped body of the first and second mould forming parts 3a, 3b are free from mutual direct contact during a pressing cycle. Consequently, said surfaces of the main rigid plate-shaped bodies are not intended to come in mutual contact and to prevent further pressing motion of the first and second forming mould parts 3a, 3b.
  • first and second mould parts 3a, 3b may still be in mutual contact during the pressing action, such as spring-loaded cutting devices and/or mould alignment devices, etc., which are not part of said surfaces of the first and second mould parts 3a, 3b.
  • Figures 8a-b schematically illustrate how a toggle press 6a may be adjusted using the mechanical adjustment mechanism 23 to obtain different levels of pressing force at maximal extended actuating position
  • figure 8c shows what happens when the distance between the front and rear structures 6b, 6c is too small
  • figure 9 shows a schematic illustration of the resulting pressing force for each of the these situations.
  • the vertical axis in the diagram of figure 9 shows pressing force provided by the toggle press 6a
  • the horizontal axis in the diagram of figure 9 shows distance 24 between the front and rear structure 6b, 6c of the toggle press 6a.
  • the distance 24 between front and rear structure 6b, 6c is adjusted to be relatively long, thereby providing a relatively low pressing force when the pressing plate 6d reaches the maximal extended actuating position.
  • the maximal extended actuating position of the toggle mechanism 6e is obtained when the first and second link members 18, 19 are aligned.
  • the resulting pressing force at this adjustment position of the mechanical adjustment mechanism 23 is marked with point A in figure 9.
  • the toggle mechanism 6e When the distance 24 between front and rear structure 6b, 6c is adjusted to be very short, the toggle mechanism 6e may be prevented from reaching the force equilibrium position, i.e. the first and second link members 18, 19 are nom-aligned, as illustrated in figure 8c.
  • the resulting pressing force at this adjustment position of the mechanical adjustment mechanism 23 is marked with point C in figure 9.
  • Pressing operation of the pressing module 6 may be performed in a variety of ways.
  • the toggle press 6a may be operated in an open loop manner, wherein no feedback of parameters such as press force or pressing member position is required.
  • FIG. 10a An example embodiment of a control system 40 suitable for controlling the toggle press 6a in an open loop manner is schematically illustrated in figure 10a.
  • the pressing actuator arrangement 6f is a hydraulic cylinder that is fluidly controlled by a solenoid-operated directional control valve 41 that is fluidly connected to a variable displacement hydraulic pump 42 and a fluid tank 43.
  • a feeding device 16, here in form of an electric motor, is provided for controlling operating of the forming wire 4c
  • a pressing member position detection device 44 is provided for ensuring that the pressing member is operated to reach the maximal forward position of the toggle mechanism 6e at each pressing event.
  • Control of the operating state of the directional control valve 41 , as well as speed of the feeding device 16, may be controlled by the electronic control system 6h, such as to provide the desired intermittent feeding of the forming wire 4c between subsequent pressing operations of the toggle press 6a.
  • the pressing member position detection arrangement may for example be a linear position encoder configured to detect the position of the pressing member 6d, or a position encoder for detecting the actuating position of the toggle mechanism 6e, or a position encoder for detecting actuating position of the pressing actuator arrangement 6f, or the like.
  • control system 40 may be configured for controlling the toggle press 6a in a closed-loop manner, as schematically showed in figure 10b.
  • the pressing actuator arrangement 6f may be controlled to simply displace the pressing member 6d to a maximal forward position, i.e. alignment angle of 180 degrees or maximal stroke state of the toggle mechanism 6e, and to have the distance 24 between front and rear structure 6b, 6c of the toggle press 6a adjusted beforehand such that the resulting press force equals a target press force .
  • the electronic control system 6h may be configured to control the pressing operation based on feedback data from a pressing force detecting or indicating arrangement, and to adjust the distance 24 between front and rear structure 6b, 6c of the toggle press 6a between consecutive pressing operations for keeping the resulting press force at a target press force .
  • variations in process parameters may be better taking care of for ensuring improved quality of the cellulose products 1.
  • Figure 10b shows, in addition to the features described with reference to figure 10a, an adjustment actuator arrangement 25 configured for driving the mechanical adjustment mechanism 23.
  • the adjustment actuator arrangement 25 may for example be an electric or hydraulic motor.
  • the system of figure 10b additionally shows a pressing force detection device 6g for providing feedback to the electronic control system 6h.
  • the toggle press 6a further includes a pressing force indicating arrangement 6g, wherein the electronic control system 6h is operatively connected to the pressing force indicating arrangement 6g and configured to control operation of the pressing actuator arrangement 6f based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g.
  • the pressing force indicating arrangement 6g typically includes some type of measurement device for measuring a level of a press force parameter. Consequently, the press force indicating feedback information typically includes, or is derived from, a measured process variable of the toggle press 6a.
  • Operational control of the pressing actuator arrangement 6f based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g may for example involve press force feedback control, position feedback control, or open loop control with automatic self-tuning between consecutive pressing cycle.
  • the pressing force indicating arrangement may for example correspond to one or more pressing force sensors of some type being located at one or more suitable position on the pressing module 6.
  • a load cell such as a strain gauge force sensor, or the like, may be provided at or within the forming mould 3, or between toggle mechanism 6e and rear structure 6c, or between the toggle mechanism 6e and the forming mould 6.
  • the pressing force indicating arrangement may correspond to a deformation sensor, such as a strain gauge sensor, which is configured for sensing deformation of for example one, two or all tie bars of the intermediate linear guiding arrangement 14.
  • a deformation sensor such as a strain gauge sensor, laser sensor, etc. may be provided for sensing deformation of the front structure 6b, or the rear structure 6c, or the pressing member 6d, or the toggle mechanism 6e.
  • the electronic control system may in some example embodiments be configured to control the adjustment actuator arrangement 25, for example for adjusting the maximal pressing force of the toggle press for a specific cellulose blank structure.
  • the toggle press may include a pressing force indicating arrangement 6g
  • the electronic control system 6h may be operatively connected to the pressing force indicating arrangement 6g, and the control system may be configured for controlling operation of the adjustment actuator arrangement, based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g, for adjusting the distance between the front structure and rear structure in the pressing direction, during a time period between consecutive pressing actions.
  • the electronic control system may adjust the maximal pressing force.
  • the electronic control system does not need active control and adjustment of the input force to the toggle mechanism 6e provided by the pressing actuator arrangement 6f for adapting the pressing force of the pressing member 6d, but may instead rely merely on active control of the adjustment actuator arrangement 25.
  • This control strategy may be implemented by adjusting the distance 24 between the front and rear structure 6b, 6c, such that the toggle pressing module 6 arrives at the target pressing force simultaneously with arriving at the at maximal stroke state of the toggle mechanism 6e.
  • the electronic control system is configured for obtaining pressing force indicating information from the pressing force indicating arrangement 6g during the pressing actions of said normal running of the toggle press 6a, and when for example the pressing force indicating information indicates that the pressing force PF is continuously, over a set of pressing cycles, above a target pressing force, the distance 24 between front and rear structure 6b, 6c of the toggle press 6a would be adjusted, during consecutive pressing actions, such that the resulting press force equals the target press force.
  • various aspects of the product forming unit U may have another design, functionality and/or layout, as schematically illustrated in figure 11.
  • the forming wire 4c may extend all the way to the pressing module 6, thereby effectively eliminating the need for an intermediate transport device 16.
  • the forming section 4d of the forming wire 4c may be arranged for extending in a horizontal direction DH.
  • the cellulose blank structure 2 is in this embodiment air-formed onto the forming section 4d, and transported from the forming section 4d by the forming wire 4c in the horizontal direction DH. After forming of the cellulose blank structure 2 onto the forming section 4d, the formed cellulose blank structure 2 is transported from the forming section 4d in the horizontal direction DH and further towards the pressing module 6.
  • the blank dry-forming module 4 of the embodiment illustrated in figure 11 has a vertical distribution direction of the cellulose fibres F from the mill 4a to the forming wire 4c through the forming chamber 4b. A vertical flow of air is thus feeding the cellulose fibres F from the mill 4a to the forming section 4d.
  • the toggle press 6a is installed with the pressing direction DP of the pressing member 6d arranged in the vertical direction Dv.
  • toggle pressing module for forming non-flat cellulose products from an air-formed cellulose blank structure has many advantages over use of large-capacity conventional toggle-less hydraulic presses, such as low-cost, low-weight, fast cycle operation and compactness. Consequently, the toggle pressing module 6 may in certain circumstances be a useful alternative to a conventional vertically standing hydraulic press.
  • the toggle pressing module 6 schematically illustrated in figures 12a-b corresponds to the toggle pressing module 6 described above with reference to figures 4a-b and reference is made to the disclosure relating to figures 4a-b for details of the toggle pressing module 6, except for the pressing actuator arrangement 6f, which here is schematically implemented as an electrically-powered ball-screw linear actuator.
  • the ball-screw linear actuator may for example comprise a rod 50 drivingly connected to an electric motor and having a helical track for holding rolling balls that may circulate in a track in the cross head 20.
  • the product forming unit U comprises a blank dry-forming module 4 with a moveable forming wire 4c, a toggle pressing module 6 with a toggle press 6a and a forming mould 3, and an electronic control system 6h operatively connected to the forming wire 4c and the toggle pressing module 6; wherein the toggle press 6a includes a pressing member 6d movably arranged in a pressing direction, a toggle-mechanism 6e drivingly connected to the pressing member 6d, a pressing actuator arrangement 6f drivingly connected to the toggle-mechanism 6e; and wherein the forming mould 3 includes a moveable first mould part 3a attached to the pressing member 6d and a second mould part 3b.
  • the method comprises a first step S1 of air-forming a cellulose blank structure 2 onto the forming wire 4c by means of the blank dry-forming module 4.
  • the method further comprises a second step S2 of feeding the air-formed cellulose blank structure 2 into a pressing area defined by the first and second, spaced apart, mould parts 3a, 3b.
  • the method comprises a third step S3 of controlling operation of the pressing actuator arrangement 6f by means of the electronic control system 6h for performing pressing operations, which involves driving the pressing member 6d in the pressing direction by means of the toggle-mechanism 6e, and thereby forming the non-flat cellulose product from the air- formed cellulose blank structure by pressing the first mould part 3a against the second mould part 3b.
  • the method comprises a fourth step S4 of controlling operation of the forming wire 4c by means of the electronic control system 6h for intermittently feeding the forming wire 4c between subsequent pressing operations.
  • Said fourth step S4 of controlling operation of the pressing actuator arrangement 6f may be performed a many different ways while still solving the problem of forming non-flat cellulose products from an air-formed cellulose blank structure using a low- cost, compact and low-weight cellulose product pressing module.
  • the toggle press 6a further includes a pressing force indicating arrangement 6g, an adjustment mechanism 23 for enabling adjustment of a distance between the first and second mould parts 3a, 3b in the pressing direction while having the toggle-mechanism 6e in a non-moving operating state, and an adjustment actuator arrangement 25 configured for driving the adjustment mechanism 23.
  • the method may then, in addition to steps S1-S4 as described with reference to figure 13, further include a fifth step S5 of controlling operation of the adjustment actuator arrangement 25 based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g.
  • the fifth step S5 of controlling operation of the adjustment actuator arrangement 25 may involve adjusting the distance between the first and second mould parts 3a, 3b during a time period between consecutive pressing actions, such that the pressing member 6d during the next pressing cycle is targeted to provide a compression force closer to a predetermined target pressing force.
  • the feedback controller 6h may be implemented in a variety of alternative ways, as known to the person skilled in the art, such as for example a P controller, PI controller, PID controller, Optimal control, such as for example Linear Quadratic (LQ) controller, or the like.
  • a P controller PI controller
  • PID controller PI controller
  • Optimal control such as for example Linear Quadratic (LQ) controller, or the like.
  • a PID (Proportional-Integral-Derivative) controller is a control loop mechanism employing feedback for providing a continuously modulated control of the process to be controlled.
  • a feedback controller such as for example a PID controller, continuously calculates an error value as the difference between a desired setpoint (SP) and a measured process variable (PV) and applies a correction based on proportional, integral, and derivative terms of said error value.
  • the setpoint (SP) may for example be a specific predetermined compression force and the measured process variable (PV) may for example be measured pressing force as detected by a strain gauge force sensor located on a tie bar 37 of the toggle press 6a.
  • the cellulose product toggle pressing module 6 may also be very useful for forming non-flat cellulose products 1 from an air-formed cellulose blank structure 2, even without the intermittent operating process of the forming wire 4c of the blank dry-forming module 4.
  • the cellulose product toggle pressing module according to the disclosure may still deliver various advantageous aspects, such as compactness, cost-efficiency, and rapid operating cycle.
  • a cellulose product toggle pressing module 6 for forming non-flat cellulose products 1 from an air-formed cellulose blank structure 2, wherein the toggle pressing module 6 comprises a toggle press 6a including a pressing member 6d movably arranged in a pressing direction, a toggle-mechanism 6e drivingly connected to the pressing member 6d, a pressing actuator arrangement 6f drivingly connected to the toggle-mechanism 6e for controlling motion of the toggle- mechanism between a retracted operating position and an extended operating position.
  • the toggle pressing module 6 further comprises a forming mould 3 including a moveable first mould part 3a attached to the pressing member 6d and a second mould part 3b, as well as an adjustment mechanism 23 for enabling adjustment of a distance between the first and second mould parts 3a, 3b in the pressing direction while having the toggle-mechanism 6e in a non-moving operating state, and an adjustment actuator arrangement 25 configured for driving the adjustment mechanism 23.
  • the toggle pressing module 6 additionally comprises a pressing force indicating arrangement 6g, and an electronic control system 6h operatively connected to the pressing force indicating arrangement 6g, the pressing actuator arrangement 6f and the adjustment actuator arrangement 25.
  • the electronic control system 6h is configured for controlling operation of pressing actuator arrangement 6f for driving the pressing member 6d in the pressing direction by setting the toggle-mechanism 6e in the extended operating position, and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part 3a against the second mould part 3b, and the electronic control system is configured for controlling operation of the adjustment actuator arrangement 25, based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g.
  • the met toggle pressing module 6 comprises: a toggle press 6a including a pressing member 6d movably arranged in a pressing direction, a toggle-mechanism 6e drivingly connected to the pressing member 6d, a pressing actuator arrangement 6f drivingly connected to the toggle-mechanism 6e for controlling motion of the toggle- mechanism between a retracted operating position and an extended operating position; a forming mould 3 including a moveable first mould part 3a attached to the pressing member 6d and a second mould part 3b; an adjustment mechanism 23 for enabling adjustment of a distance between the first and second mould parts 3a, 3b in the pressing direction while having the toggle-mechanism 6e in a non-moving operating state; an adjustment actuator arrangement 25 configured for driving the adjustment mechanism 23; a pressing force indicating arrangement 6g; and an electronic control system 6h operatively connected to the pressing force indicating arrangement 6g, the pressing actuator
  • the method comprises: air-forming a cellulose blank structure 2 onto the forming wire 4c by means of the blank dry-forming module 4; feeding the air- formed cellulose blank structure 2 into a pressing area defined by the first and second, spaced apart, mould parts 3a, 3b; controlling operation of the pressing actuator arrangement 6f for performing pressing operations, which involves driving the pressing member 6d in the pressing direction by setting the toggle-mechanism 6e in the extended operating position, and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part 3a against the second mould part 3b; and controlling operation of the adjustment actuator arrangement 25, based on pressing force indicating feedback information received from the pressing force indicating arrangement 6g.
  • Adjustment of a distance between the first and second mould parts 3a, 3b in the pressing direction while having the toggle-mechanism 6e in a non-moving operating state means that the adjustment is not caused by movement of toggle-mechanism, but caused by some other feature.
  • the step of controlling operation of pressing actuator arrangement for driving the pressing member in the pressing direction by setting the toggle- mechanism in the extended operating position generally involves setting the toggle- mechanism in a maximal extended operation position.
  • Forming mould 19 Second link member
  • Second mould part 40 21 Cross head link member
  • Blank dry-forming module 22 Alignment angle
  • Feeding structure 34 First arrow
  • Feeding device 42 Pump 43: Tank 20 D P : Pressing direction
  • Position detection device Du Upwards blank forming
  • Threaded rod M F Feeding mode 51: Buffering arrangement MINT: Intermittent flow mode

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Mechanical Engineering (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Polysaccharides And Polysaccharide Derivatives (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Reinforced Plastic Materials (AREA)
  • Paper (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Unité de formation de produit (U) pour fabriquer des produits cellulosiques non plats (1) à partir d'une structure d'ébauche de cellulose formée à l'air (2). L'unité de formation de produit (U) comprend un module de formage à sec d'ébauche (4) avec un fil de formage mobile (4c), un module de pression à bascule (6) avec une presse à bascule (6a) et un moule de formage (3), et un système de commande électronique (6h) relié fonctionnellement au fil de formage (4c) et à la presse à bascule (6a). Le module de formage à sec d'ébauche (4) est configuré pour former à l'air la structure d'ébauche de cellulose (2) sur le fil de formage (4c). La presse à bascule (6a) comprend un élément de pression (6d) agencé de façon mobile dans une direction de pression, un mécanisme à bascule (6e) relié par entraînement à l'élément de pression (6d), un agencement d'actionneur de pression (6f) relié par entraînement au mécanisme à bascule (6e). Le moule de formage (3) comprend une première partie de moule mobile (3a) fixée à l'élément de pression (6d) et une seconde partie de moule (3b). Le système de commande électronique (6h) est configuré pour commander le fonctionnement de l'agencement d'actionneur de pression (6f) pour effectuer des opérations de pressage, qui impliquent l'entraînement de l'élément de pression (6d) dans la direction de pressage au moyen du mécanisme à bascule (6e), et formant ainsi le produit cellulosique non plat à partir de la structure d'ébauche de cellulose formée à l'air par pression de la première partie de moule (3a) contre la seconde partie de moule (3b). Le système de commande électronique (6h) est en outre configuré pour alimenter par intermittence le fil de formage (4c) entre des opérations de pressage ultérieures.
PCT/EP2022/059510 2021-04-15 2022-04-08 Module de pressage à bascule de produit cellulosique et son procédé d'utilisation WO2022218872A1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
AU2022258535A AU2022258535A1 (en) 2021-04-15 2022-04-08 A cellulose product toggle pressing module and method for using the same
EP22720730.5A EP4323182A1 (fr) 2021-04-15 2022-04-08 Module de pressage à bascule de produit cellulosique et son procédé d'utilisation
CA3215281A CA3215281A1 (fr) 2021-04-15 2022-04-08 Module de pressage a bascule de produit cellulosique et son procede d'utilisation
CN202280028110.1A CN117203044A (zh) 2021-04-15 2022-04-08 一种纤维素产品的肘节压制模块及其使用方法
JP2023562983A JP2024514892A (ja) 2021-04-15 2022-04-08 セルロース製品トグルプレスモジュールおよびこれを使用するための方法
US18/285,619 US20240181739A1 (en) 2021-04-15 2022-04-08 Cellulose product toggle pressing module and method for using the same
TW111114474A TW202302330A (zh) 2021-04-15 2022-04-15 纖維素製品之肘節按壓模組及其使用方法

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
EPPCT/EP2021/059811 2021-04-15
PCT/EP2021/059811 WO2022218531A1 (fr) 2021-04-15 2021-04-15 Procédé de fabrication de produits cellulosiques et unité de formation de produits pour la fabrication de produits cellulosiques
PCT/EP2021/059810 WO2022218530A1 (fr) 2021-04-15 2021-04-15 Module de pressage à genouillère de produit de cellulose et son procédé d'utilisation
EPPCT/EP2021/059810 2021-04-15
SE2151618A SE2151618A1 (en) 2021-12-23 2021-12-23 A method for producing a cellulose product and a cellulose product
SE2151618-2 2021-12-23

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PCT/EP2022/059512 WO2022218873A1 (fr) 2021-04-15 2022-04-08 Procédé de formage à sec de produits de cellulose à partir d'une structure d'ébauche de cellulose dans une unité de formage de produit, et unité de formage de produit

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US (2) US20240181740A1 (fr)
EP (3) EP4349583A1 (fr)
JP (2) JP2024518278A (fr)
AU (2) AU2022259460A1 (fr)
CA (2) CA3215284A1 (fr)
MX (1) MX2023012057A (fr)
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CA3215281A1 (fr) 2022-10-20
TW202306731A (zh) 2023-02-16
US20240181739A1 (en) 2024-06-06
AU2022258535A1 (en) 2023-10-05
TW202302330A (zh) 2023-01-16
JP2024514892A (ja) 2024-04-03
CA3215284A1 (fr) 2022-10-20
WO2022218873A1 (fr) 2022-10-20
MX2023012057A (es) 2023-10-23
US20240181740A1 (en) 2024-06-06
EP4323182A1 (fr) 2024-02-21
JP2024518278A (ja) 2024-05-01
EP4349583A1 (fr) 2024-04-10
AU2022259460A1 (en) 2023-10-05

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